3 roll bender - diy

[JEEPSERIOUS]

I had this build posted on our local wheeling a site TNTGP.COM, Corey a.k.a. "YJ and Corey" which is a founding member said he would stop talking to me until i posted on pirate. so here's my first post, hope you enjoy it. and Corey :flipoff2:

so, to make a unique exo cage, one needs a unique tool. since i don't want to spend 1200 + dollars on a 3 roll bender, i decided to build one

we looked at what was on the market, 1100 plus shipping and exchange.

http://i649.photobucket.com/albums/uu218/beastfrombackeast/6-1.jpg

but they make nice long radius bends

http://i649.photobucket.com/albums/uu218/beastfrombackeast/7-1.jpg

Me and Lane sat down one night and came up with a CAD drawing, we sourced out a water jet, and this is what came out of it

http://i649.photobucket.com/albums/uu218/beastfrombackeast/1-1.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/2-1.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/5-1.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/4-1.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/3-1.jpg

steel shmeel, this is what i have, it may not look like much but hopefully after tonight we will have machined some roller dies from it. This material is available from Johnston industrial plastics, it's called nylatron GSM, a moly impregnated nylon which is super dense, self lubricating (not wet though) and wear resistant. the guy on the phone said i may not need a bushing for the thru bolt, although i will use bearings. a set of steel dies 400+ canadian, 1 foot of 4" dia. nylatron 60 bucks. here are some links
RADIUS CALCULATOR
http://www.handymath.com/cgi-bin/rad2.cgi?submit=Entry

NYLATRON SPECS
http://www.jmjprofile.com/PlasticMaterialSpecs2.htm#nylatronSpecs

Johnston Plastics
http://www.johnstonplastics.com/

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01298.jpg

[JEEPSERIOUS]

we cut a piece with a perfect .750 inch radius, then i ground a relief and filed the edges sharp
http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01309.jpg
i first cut my depth and width and ruf cut with a small tool, after the basic shape was attained, i used the cutter we had made to get the radius just right.
http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01308.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01313.jpg

then parted the individual roller, they will be faced to width and fitted with bearings
http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01319.jpg

bearings set in place on the bottom rollers, the other upper roller will have a key way broached, will use a 7/8 inch keyed shaft and the bearings will be set in the top roller assembly
http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01338.jpg

starting to look like a bender, just have to make the top assembly and cut some tube for seperators.
If your wondering what the 2 large nuts are for, 1 will be welded to the top end of the threaded rod the other at the end of the keyed shaft, this will be so i can use the same handle for each action

http://i649.photobucket.com/albums/uu218/beastfrombackeast/c2.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/c1.jpg

back from my parents place in scotia, while there i had a chance to do some machine work for roll bender top assembly.

using a boring bar i enlarged the center hole to .875 so i can fit a 7/8 keyed shaft through it.
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta11.jpg

broached a key way
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta12.jpg

i used the band saw to rough cut the 2 top pieces slightly larger than 4.5" x 4.0", each plate is 1" thich. one of these will be mounted solid to very top of the bender and will be threaded, the other will be part of the top roller assembly.
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta13.jpg

[JEEPSERIOUS]

i milled the pieces down to 4.5" x 4.0"
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta14.jpg

one of the plates were drilled so the threaded rod could pass through
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta15.jpg

i cut the sides of the assembly in the same fashion as above, then placed them in a 4 jaw chuck so i could bore holes to fit bearings in them
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta16.jpg

used a boring bar to get the holes to 1.995" so the bearing will have an interference fit, the bearings are 2.000"
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta17.jpg

pressed the bearings in
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta20.jpg
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta19.jpg

just need to take these parts and put them together with the side plates
http://i649.photobucket.com/albums/uu218/beastfrombackeast/ta21.jpg

[JEEPSERIOUS]

all pieces are together and fit just right, i will test it once i get some tube, still need to make a handle
http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01604.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01605.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01608.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01615.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01618.jpg

[JEEPSERIOUS]

with the help of some friends and access to some special equipment we have created a working 3 roll bender which saved us over $1000 and created a tool for the club. thanks to all who helped. check out the vid

http://i649.photobucket.com/albums/uu218/beastfrombackeast/th_ROLLBENDERVID.jpg (http://s649.photobucket.com/albums/uu218/beastfrombackeast/?action=view&current=ROLLBENDERVID.flv)


here's a few pics

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test1.jpg


http://i649.photobucket.com/albums/uu218/beastfrombackeast/test3.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test4.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test5.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test7.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/firstrollbentpieces.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01764.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01767.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01773.jpg


here are some links
RADIUS CALCULATOR
http://www.handymath.com/cgi-bin/rad2.cgi?submit=Entry

NYLATRON SPECS
http://www.jmjprofile.com/PlasticMaterialSpecs2.htm#nylatronSpecs

Johnston Plastics
http://www.johnstonplastics.com/

[Bones]

Very nice work on the roller, but that rear tube work is god awfull! :barf:

[SpineTx]

In! thanks.

Seriously...when will you have these for sale?:grinpimp::grinpimp::grinpimp:

[513]

Great tech! Definitely saving this one for sure!

[95geo]

Very nice work on the roller, but that rear tube work is god awfull! :barf:

X2 :laughing:

rolled bends are good if you can incorporate them without drawing attention to them... BTF's KOH rig, Zukizzy's rig, Rockbug all come to mind....

remember, less is more. :grinpimp:

awesome roll bender, it gives me ideas! I just dont like rolled tube enough to make one. :homer:

[Flatline's Up!]

nice roller build...:grinpimp:

you know your truck will now be known as "bubblebutt" from now on... :flipoff2::D

[Pdaddy]

In! thanks.

Seriously...when will you have these for sale?:grinpimp::grinpimp::grinpimp:


Seriously :D


Cool tool build !

[Dustin]

Great first posts. I have a few questions. What is the tubing that you are bending, how much have you rolled so far, how are the dies holding up, and are you willing to share the cad drawings that you used for the side plates? Thanks.

[JEEPSERIOUS]

Great first posts. I have a few questions. What is the tubing that you are bending, how much have you rolled so far, how are the dies holding up, and are you willing to share the cad drawings that you used for the side plates? Thanks.

1.5" x .120" hrew, what you see in the pic is what i have done so far. the dies are holding up fine, i'll see about the drawings... talk to ya later

[Dustin]

1.5" x .120" hrew, what you see in the pic is what i have done so far. the dies are holding up fine, i'll see about the drawings... talk to ya later

Thanks.

[78stepsideUAK10]

Badass

:smokin:

[YJ_and_Corey]

X2 :laughing:

rolled bends are good if you can incorporate them without drawing attention to them... BTF's KOH rig, Zukizzy's rig, Rockbug all come to mind....

remember, less is more. :grinpimp:

awesome roll bender, it gives me ideas! I just dont like rolled tube enough to make one. :homer:

Once it is done it'll look good - it's hard to see the completed project at this stage. Besides - if we all had rigs that looked the same, wheeling would be pretty lame :flipoff2:

I will say this - his roll bender works really well. It pulls the tubing through like butter, and rolls it with ease.

[JeepFreak21]

Fawking awesome!
http://www.slicky.net/smilies/cooleek3.gif
Billy

[heepr]

Cool tool tech.

but the rig looks like a dome tent.

[rockkiller]

X2 :laughing:

rolled bends are good if you can incorporate them without drawing attention to them... BTF's KOH rig, Zukizzy's rig, Rockbug all come to mind....

remember, less is more. :grinpimp:

awesome roll bender, it gives me ideas! I just dont like rolled tube enough to make one. :homer:

who are you :shaking: i have'nt seen anything you have built :flipoff2:

[fledgling666]

very cool...

[Panthers65]

The bender looks great. Seems like it would be easier to buy/beef up/modify the Harbor Freight $150 roller.... There was a review in the tools section that wasn't half bad. Nice job either way!

[SeaBass44]

we have a tool section............

[Killerpee]

Nice job on documenting the build! Welcome to Pirate:flipoff2:

[Ramrock]

Cool tool build.

But those are only good for ROLLING out circles or half circles. Not bending. You do that with a tub bender.

[YJ_and_Corey]

Cool tool build.

But those are only good for ROLLING out circles or half circles. Not bending. You do that with a tub bender.

Well - the tubing is no longer straight - so I guess it's now BENT isn't it?

And what the hell is a "tub bender"? Sheesh.

[extreme townie]

great work. how much do you have in it, less the labor? in us dollars please.

[JEEPSERIOUS]

great work. how much do you have in it, less the labor? in us dollars please.

thanks for the props, contact your local suppliers for cost on materials.

these will cost you the most
4" diameter x 12" solid Nylatron
53" x 17" x 3/8" steel plate
4" x 10" x 1" steel plate
4" x 9" x 1/2" steel plate

add 50 to 100 dollars for hardware
bearings
collars
acme threaded rod
keyed shaft
keystock
nuts and bolts

[kidkrawler]

Nice build!!!

[BAILEIGH INC.]

with the help of some friends and access to some special equipment we have created a working 3 roll bender which saved us over $1000 and created a tool for the club. thanks to all who helped. check out the vid

http://i649.photobucket.com/albums/uu218/beastfrombackeast/th_ROLLBENDERVID.jpg (http://s649.photobucket.com/albums/uu218/beastfrombackeast/?action=view&current=ROLLBENDERVID.flv)


here's a few pics

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test1.jpg


http://i649.photobucket.com/albums/uu218/beastfrombackeast/test3.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test4.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test5.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/test7.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/firstrollbentpieces.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01764.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01767.jpg

http://i649.photobucket.com/albums/uu218/beastfrombackeast/DSC01773.jpg


here are some links
RADIUS CALCULATOR
http://www.handymath.com/cgi-bin/rad2.cgi?submit=Entry

NYLATRON SPECS
http://www.jmjprofile.com/PlasticMaterialSpecs2.htm#nylatronSpecs

Johnston Plastics
http://www.johnstonplastics.com/


Nice looking work!

Good job!

[BB1980]

HOLY MOLY, why do you reply with ALL of his pictures, lol! :homer:

[Swag Off Road]

Nice Job :smokin:

[1TON73K5]

Bad ass tube roller, very nice design for sure. I want to build one, I just don't know how much I will actually use one. I might it the future.

[uglyscout]

Bad ass tube roller, very nice design for sure. I want to build one, I just don't know how much I will actually use one. I might it the future.

As has been said already in this thread for guy like us that might only use one now and again, Harbor Freight has one.

Full Pirate review with a dude that is making custom dies to fit the HF roller.

http://www.pirate4x4.com/forum/showthread.php?t=737981

Not saying the roller in this thread isn't super bad ass!!!

[1TON73K5]

As has been said already in this thread for guy like us that might only use one now and again, Harbor Freight has one.

Full Pirate review with a dude that is making custom dies to fit the HF roller.

http://www.pirate4x4.com/forum/showthread.php?t=737981

Not saying the roller in this thread isn't super bad ass!!!


Oh yes I have read the thread, I know all about the HF roller. Guy at work bought one and we made custom dies for his. He loves it for what he does. Gates and whatnot. I just hate buying HF stuff. I know, I know, it's actually one of the better tools that have but still. I could make one at work no problem. We have a bunch of 1" Aluminum plate just laying around waiting to be used for.......something, like a tube roller. I have enough projects on my plate. Taking on another one is not want I want to do right now.